Advice on rust repair technique needed

[Datto-Zed]

I need some advice on how to tackle the repair of a number of patches on rust on a KE30 Corolla. I'll post a picture of each spot in question and description of what it is. Any input on how to repair each of these sections would be great.

http://users.bigpond.net.au/oceanz/z/rust2/DCP_7832.jpg

Front 1/4 panel just bellow the windscreen. I'd be thinking you'd plate over the rear, treat with POR15, bog then paint?

http://users.bigpond.net.au/oceanz/z/rust2/DCP_7833.jpg

Bottom of front 1/4. Underlying metal is heavily rusted, has had a dodgy "repair" job done previously. I'd guess this will need a whole new piece section fabricated, or find a replacement panel?

http://users.bigpond.net.au/oceanz/z/rust2/DCP_7834.jpg

Left hand door. Not lookin' too good.

http://users.bigpond.net.au/oceanz/z/rust2/DCP_7835.jpg

Corner of rear window. Can you get away with treating the rust, then just bogging, or would it require new metal to be welded in?

http://users.bigpond.net.au/oceanz/z/rust2/DCP_7837.jpg

RH side on engine bay, inside of wing. After removing the 1/4 panel we found the engine wind was packed full of dirt/mud. No wonder it had rusted through.

http://users.bigpond.net.au/oceanz/z/rust2/DCP_7841.jpg

LH chassis rail. The section rusted through is only a very thin panel and I am guessing is not really a structural part of the rail itself (?).

http://users.bigpond.net.au/oceanz/z/rust2/DCP_7842.jpg

Radiator support. Not looking good at all here. Plate? Fabricate? Cut this section out of another corolla?
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If you're wondering why bother save this car considering all the rust.....the rest of it is really good. The interior is really immaculate, looks like the day it left the factory and mechanically it's great.

[hotgemini]

In my mildly experienced opinion, 7835 and 7842 will be the hardest, if you're going to the trouble of welding new metal in (and it is the only 'proper' option) anywhere, then you might as well do it everywhere.

[Che Castro]

Not really familiar with the sheetmetal of corollas but

The first one looks a bit difficult because it looks like its sandwiched between two sheets (probably the reason it retained water and rusted in the first place)

Second one looks pretty bad as the whole thing looks like its been bogged up. Difficult to tell until you strip it entirely to see where there's steel.

Third, door looks easy as you could just cut out the rust and graft in a replacement section (looks easy to make as it is straight and L shaped in section)

Fourth - I'll guess it'll be even worse when you take out the window rubber? Kind of difficult to do as its curved. Could try to graft one from another body?

Fifth - cant really tell, might be worth cutting out the rust with a cutoff wheel and seeing where the steel starts to get good.

Six - Chassis rail looks easy ish.. depends how good you are at welding above head Must be pretty thin steel for the chassis rail to rust through?

Seven - Looks harder to fabricate, prob need a shrinking tool to get those curves exactly. Better to get one from another car or just fabricate something non original.

Could you just get another body and swap over the mechanicals/interior?

[browny]

Would this help with 7833 (Rare Spares):

Product Code: RP603
Price inc GST($AUD): $43.88 EA
Description: FRONT FENDER LOWER COROLLA KE30 .LH.

I'm with hotgemini - new metal is the only way to go. I'd be looking for aftermarket rust repair sections or repairs using sections of original panels.

[Datto-Zed]

Thanks guys.

browny: That'd be spot on. What places (other than rare spares) do you know of that have rust repair sections for little old corollas?

[browny]

None. Rares was just a lucky guess.

[crx2gen]

I thought you knew everything there was to know about rust DZ?

[Datto-Zed]